System and method for supporting an in-tank fuel pump

ABSTRACT

An in-tank fuel pump assembly and mounting system is disclosed which may be configured for mounting inside a fuel tank. The assembly includes a pump housing, pump mounted to the housing, and pressure relief valve. The housing may comprise upper and lower pump housing units coupled together. The upper housing unit is configured for mounting to a tank opening, which in one implementation may be the fuel fill opening. The lower housing unit extends into the tank to approximately the bottom of the tank. A fuel fill fluid pathway is created through the housing for adding fuel to the tank while the pump assembly remains in situ. The upper housing unit may include a removable fuel cap. The pump is capable of pressurizing the fuel to pressures suitable for use in fuel injection type engines. A resiliently deformable in-tank fuel filter may be coupled to the pump.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. ProvisionalApplication No. 62/569,206 filed Oct. 6, 2017; the entirety of which isincorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to fuel delivery systems forengine-driven devices and apparatuses, and more particularly to a systemand method for supporting an in-tank type of fuel pump.

Gasoline engines with fuel injection require liquid fuel to be deliveredto the engine at a higher and steadier pressure than typical carburetedgasoline engines. Because of this, a different type of fuel pump is usedwith fuel injected engines. Fuel pumps for fuel injected engines aremost often electrically driven, and they operate at a constant speedwhenever the power is switched on. The pump is designed to supply morefuel than the engine can consume, and the continued over-pumpinggenerates pressure in the fuel supply line. A relief valve holds thepressure at the desired limit, and relieves any excess pressure byallowing some fuel to run back to the tank. Some fuel tanks may befabricated in two halves to allow the pump to be mounted first insidethe tank before the tank pieces are assembled. Other tanks may beone-piece molded fabrications. In addition to the fuel fill opening,prior fuel tanks generally have a separate opening dedicatedspecifically for the fuel pump.

An improved system and method is desired for mounting a fuel pump of aliquid fuel delivery system inside the fuel tank.

SUMMARY OF THE DISCLOSURE

A fuel pump assembly and mounting system is disclosed which may beconfigured and operable for mounting the pump assembly inside a fullyassembled fuel tank. The fuel pump assembly may be mounted to the tankin a sufficiently rigid manner for fuel injection engine applications.In one aspect, the fuel pump may be configured for mounting in the sameopening used for fuel fill. Advantageously, this dual-use single openingobviates the need for a separate opening for the fuel pump alone as inpast designs. This results in a more compact construction and eliminatesthe separate tank opening for the pump which creates a secondaryconnection site for potential fuel leakage in addition to addedfabrication costs. The fuel pump assembly may form part of a liquid fueldelivery or supply system for supplying fuel to an engine-operateddevice or apparatus. In one configuration, the apparatus may be aself-driven vehicle capable of moving over a liquid or solid surface orterrain. The fuel source may be gasoline in one implementation.

In one aspect, a fuel pump assembly comprises: a pump housing configuredfor mounting to a fuel fill opening of a fuel tank; at least a portionof the pump housing defining a fuel fill fluid pathway between the fuelfill opening and an interior of the fuel tank; and a fuel pump mountedto the pump housing for dispensing fuel from the fuel tank through thefuel fill opening. In one implementation, a discharge flow tube isfluidly coupled to the fuel pump for discharging the pressurized fuelfrom the pump, the discharge flow tube being routed through the fuelfill fluid pathway in the pump housing.

In another aspect, a fuel supply system comprises: a tank including areservoir for holding fuel and a fuel fill opening fluidly communicatingwith the reservoir; a fuel pump system mounted in the tank through thefuel fill opening, at least a portion of the fuel pump system defining afuel fill fluid pathway between the fuel fill opening and the reservoir;and the fuel pump system comprising a fuel pump disposed in thereservoir, the fuel pump operable to dispense fuel from the tank throughthe fuel fill opening.

In another aspect, a method for mounting a fuel pump in a fuel tankcomprises: providing a pump housing including a fuel pump and an inletfuel filter coupled to the fuel pump, the filter being resilientlydeformable between a flattened unfolded condition and a foldedcondition; aligning the pump housing with a fuel fill opening in a fueltank, the filter being in the unfolded condition; inserting a lowerportion of the pump housing through the fuel fill opening; engaging thefilter with the fuel tank at the fuel fill opening, the engagementcollapsing the filter from the unfolded condition to the foldedcondition; and spreading the filter from the folded condition to theunfolded condition once the filter disengages the fuel tank at the fuelfill opening; wherein the pump housing is positioned through the fuelfill opening.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the example (“exemplary”) embodiments will be describedwith reference to the following drawings where like elements are labeledsimilarly, and in which:

FIG. 1 is a perspective view of a fuel pump assembly and fuel supplysystem according to the present disclosure;

FIG. 2 is a cutaway view thereof;

FIG. 3 is an exploded view thereof;

FIG. 4 is a side view thereof;

FIG. 5A is a transverse cross-sectional view thereof;

FIG. 5B is a perspective cross-sectional thereof;

FIGS. 6A and 6B are exploded top and bottom perspective viewsrespectively of the fuel pump assembly;

FIG. 7 is a cross-sectional view of the pump assembly;

FIG. 8A is a first side view of a tubing coupler of a fuel dispensingnozzle assembly;

FIG. 8B is a second side view thereof;

FIG. 8C is a third side view thereof;

FIG. 8D is a front end view thereof;

FIG. 8E is rear end view thereof;

FIG. 9A is a first side view of the fuel pump with attached fuel filter:

FIG. 9B is a second side view thereof;

FIG. 9C is a third side view thereof;

FIG. 9D is a top view thereof;

FIG. 10A is a first side view of a retainer for frictionally coupling alower pump housing unit to an upper pump housing unit of the pumphousing;

FIG. 10B is a second side view thereof;

FIG. 10C is a third side view thereof;

FIG. 10D is a first end view thereof;

FIG. 10E is a second end view thereof;

FIG. 11A is a first side view of a flow tube;

FIG. 11B is a second side view thereof;

FIG. 11C is a third side view thereof;

FIG. 11D is a top view thereof;

FIG. 11E is a bottom view thereof;

FIG. 12A is a top view of the upper pump housing unit;

FIG. 12B is a first side view thereof;

FIG. 12C is a second side view thereof;

FIG. 12D is a transverse cross-sectional view thereof;

FIG. 12E is a top perspective view thereof;

FIG. 12F is a first bottom perspective view thereof;

FIG. 12G is a second bottom perspective view thereof;

FIG. 13A is a first perspective view of the lower pump housing unit;

FIG. 13B is a second perspective view thereof;

FIG. 13C is a first side view thereof;

FIG. 13D is a second side view thereof;

FIG. 13E is a third side view thereof;

FIG. 13F is a top view thereof;

FIG. 13G is a bottom view thereof;

FIG. 13H is a fourth side view thereof;

FIG. 13I is a side cross-sectional view thereof;

FIG. 14A is a first sequential view for a process or method ofassembling the pump assembly;

FIG. 14B is a second sequential view thereof;

FIG. 14C is a third sequential view thereof;

FIG. 14D is detailed view taken from FIG. 14C;

FIG. 14E is a fourth sequential view of the process or method ofassembling the pump assembly;

FIG. 14F is a fifth sequential view thereof;

FIG. 14G is a sixth sequential view thereof;

FIG. 14H is a seventh sequential view thereof;

FIG. 14I is a eighth sequential view thereof;

FIG. 15A is a first sequential view for a process or method of couplingthe lower pump housing unit to the upper pump housing unit using theretainer;

FIG. 15B is a second sequential view thereof;

FIG. 15C is a third sequential view thereof;

FIG. 15D is a fourth sequential view thereof;

FIG. 15E is a fifth sequential view thereof;

FIG. 15F is a perspective view of an alternative process or method ofcoupling the lower pump housing unit to the upper housing unit using theretainer;

FIG. 16 is a top perspective view showing lower and upper pump housingunits assembled to form the pump housing;

FIG. 17 is a front perspective view of the assembled pump housing;

FIG. 18 is cross-sectional view thereof taken from FIG. 17;

FIG. 19A is an exploded view of the pump housing assembly including afuel cap and tubing coupler of a fuel dispensing nozzle assembly;

FIG. 19B is a bottom perspective view of the fuel cap;

FIG. 19C is a top perspective view of the upper housing unit of the pumphousing on which the fuel cap is mounted;

FIG. 19D shows the fuel cap in a rotatably mounted position on the upperhousing unit;

FIG. 20 is a cross-sectional view of the pump housing showing anintegral fuel vapor trap system and flow path;

FIG. 21A is a first sequential view of installing a fully assembled pumpassembly into the fuel tank through the fuel fill opening, the filterbeing shown in an unfolded condition;

FIG. 21B is a second sequential view thereof, the filter being shown ina folded condition;

FIG. 21C is a third sequential view thereof;

FIG. 21D is a fourth sequential view thereof;

FIG. 21E is a fifth sequential view thereof;

FIG. 21F is a sixth sequential view thereof;

FIG. 22 is a schematic diagram showing an engine-operated device orapparatus with liquid fuel delivery system according to the presentdisclosure;

FIG. 23A is a top perspective view of an alternative fuel cap usablewith the fuel pump assembly which incorporates a carbon fuel vaporcanister;

FIG. 23B is a bottom perspective view thereof;

FIG. 23C is a side view thereof;

FIG. 23D is a transverse cross-sectional view thereof; and

FIG. 24 is a perspective view of the pump housing showing options forproviding electrical power to the pump.

All drawings are schematic and not necessarily to scale. A reference toa figure number herein comprised of a set of multiple figures sharingthe same figure number but with different alphabetic suffixes shall beconstrued as a reference to all those figures in the set unlessexpressly noted otherwise.

DETAILED DESCRIPTION

The features and benefits of the invention are illustrated and describedherein by reference to example (“exemplary”) embodiments. Thisdescription of example embodiments is intended to be read in connectionwith the accompanying drawings, which are to be considered part of theentire written description. Accordingly, the disclosure expressly shouldnot be limited to such embodiments illustrating some possiblenon-limiting combination of features that may exist alone or in othercombinations of features.

In the description of embodiments disclosed herein, any reference todirection or orientation is merely intended for convenience ofdescription and is not intended in any way to limit the scope of thepresent invention. Relative terms such as “lower,” “upper,”“horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and“bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing underdiscussion. These relative terms are for convenience of description onlyand do not require that the apparatus be constructed or operated in aparticular orientation. Terms such as “attached,” “affixed,”“connected,” and “interconnected,” refer to a relationship whereinstructures are secured or attached to one another either directly orindirectly through intervening structures, as well as both movable orrigid attachments or relationships, unless expressly describedotherwise.

The overall purpose of locating a fuel pump for fuel injection engineswithin the fuel tank is so that it runs cooler. Electric fuel pumps runcontinuously, and generate heat in the process of providing pressurizedfuel. If fuel is heated too much, it can vaporize causing pockets ofvaporous (non-liquid) fuel which become difficult to pump out. Theinternal mechanisms of these pumps cannot accommodate the thin andlighter vapor in the same way as liquid, which is more viscous, and thuspumping of vapor is difficult. Locating the pump within the fuel tankmeans that it will be bathed in liquid fuel, which will act to cool theoutside of the pump housing, and also cool the fuel within the pump.

Another reason to locate a fuel pump within a fuel tank is to put it ata lower altitude or elevation than the fuel surface level. This meansthat the incoming fuel does not need to be lifted by the pump. Liftingthe fuel with suction from a pump causes negative pressure in the drawtube. When fuel is under negative pressure it can vaporize, causing thesame non-liquid fuel pockets that can disrupt the pumping action. If thepump is below the fill-level of the fuel, a slight positive pressure isassured at the draw tube, and the risk of vaporization is greatlyreduced.

There are many different ways that a fuel pump can be suspended insideof a fuel tank, but it generally needs to be robust enough to supportthe mass of the pump under vibration and acceleration loads generated bythe application (vehicle, tractor, utility machine, or other enginepowered device) and generated by the actions of the application (roadtravel loads, stump grinding loads, ground tamper loads, etc.). Supportneeds to be sufficient to hold the pump in place without fatigue failureof the mounting structure for the desired life of the engine-poweredapplication or of the pump (if less than the overall useable life). Thesuspension also needs to be somewhat compliant, so that highacceleration levels are not directly imparted onto the pump, as highacceleration levels that are sustained for long periods of time candamage the internal mechanisms of the pump.

FIGS. 1-9 depict one implementation of an in-tank fuel pump assembly andfuel supply system according to the present disclosure. The system maygenerally comprise fuel tank 20 and fuel pump assembly 100 disposed atleast partially therein. Fuel tank 20 may include a substantially hollowbody defining a top wall 21, opposing bottom wall, a plurality ofperipheral sidewalls 23 extending around the body between the top andbottom walls, and an internal cavity or reservoir 26 for storing areserve of fuel used to power a fuel-injected engine of anengine-operated device. The fuel may be gasoline in one example;however, other types of liquid fuels may be stored and pumped. Acloseable fuel fill opening 28 may be formed in top wall 21 of the tank20 for adding fuel to the reservoir 26. Fuel fill opening defines avertical mounting axis VA for reference. Accordingly, in oneimplementation, the fuel fill opening 28 may also serve for mounting thefuel pump assembly 100 according to the present disclosure.

In the non-limiting configuration shown, the tank 20 may be of atwo-piece construction including an upper half-section 24 and a lowerhalf-section 25 joined at an intermediary seam 27 therebetween. Seam 27may extend perimetrically and continuously around the sidewalls 23. Theseam may be a crimped, soldered, brazed, welded, adhesively bonded,mechanically fastened (e.g. fasteners, clamps, etc.), or otherwise toclose the seam, which is at least leak resistant to prevent seepage offuel therethrough. Fuel tank 20 may be formed of a suitable metallic ornon-metallic material. In other possible constructions, the fuel tankbody may be formed as a seamless monolithic unitary structure which maybe formed of molded plastic. The example fuel tank is expressly notlimited to either a seamless or seamed tank construction.

Fuel pump assembly 100 generally includes a fuel pump 101, pump housing102 supporting the pump, and a fuel filter 103 fluidly coupled to thepump. Pump 101 may be any suitable type of submersible electric in-tankfuel pump suitable for pumping to supply pressures desired for fuelinjection type ignition systems. The supply pressure will typically begreater than the pressure at which fuel is added to the fuel tankreservoir from either a fuel can or fueling nozzle at a service station.Pump 101 includes electrical connectors (not shown) for coupling topower wires routed through pump housing 102 and/or fuel tank 20 from anexternal power source associated with the engine assembly. Pump 101 mayhave a generally vertically elongated and cylindrical casing 101, adischarge nozzle 106 at a top end of the casing, and a suction nozzle108 at a bottom end. Suction nozzle 108 is fluidly coupled to fuelfilter 103. The nozzles 106, 108 may have a cylindrical shape. Otherarrangements and locations of the nozzles may be used. Pump 101 drawsand discharges fuel from the fuel tank 20 vertically and parallel tovertical centerline VA of the tank. The pump casing may be made ofplastic in one example; however, other materials may be used. Pump 101is configured and operable to dispense a flow of pressurized fuel whichis delivered to the fuel injection system of the engine.

Fuel filter 103 may be directly coupled to suction nozzle 108 whichlends to a compact and efficient design. In one configuration, fuelfilter 103 may have a polygonal configuration such as without limitationan elongated rectangular shape with a thickness. Filter 103 includesopposing end portions 109 and an intermediate portion 110 therebetween.Filter 103 has a length greater than the diameter of the fuel pump 101and may be symmetrically positioned on the pump suction nozzle 108 suchthat the end portions 109 extend perpendicularly to the pump and pumphousing 102. In one embodiment, filter 103 may be resiliently deformableand constructed of a material having an elastic memory. This allows theopposing end portions 109 to be collapsed and folded upwards into afolded state or condition for insertion into the fuel tank 20 throughfuel fill opening 28 via engagement with the tank at opening. The filterwill spring back and spread to its original unfolded flattened state orcondition once the filter fully enters the tank reservoir 26 anddisengages the fuel tank at the fuel fill opening, as further describedherein. Filter 103 may therefore be movable and deformable between afolded condition and a flattened condition. In one construction,intermediate portion 110 may have a thickness less than end portions 109to provide additional flexibility for folding the filter. The filter 103allows fuel to be drawn from the fuel tank reservoir 26 via suctionproduced by pump 101 and capillary action. The fuel passes from thefilter 103 through the suction nozzle 108 of the pump 101. Any suitabletype of absorbent and porous filter media or material having resilientlydeformable characteristics may be used for filter 103. Examples includeporous polymeric foams or other materials. The filter may fabricatedfrom a thin cast polymeric material in one construction, with poresformed in the casting process.

Pump housing 102 may be a two-piece construction in some implementationsincluding an upper housing unit 105 and a lower housing unit 104. Upperand lower housing units 105, 104 are configured for coupling together,as further described herein. Pump housing 102 may have a generallytubular configuration with various openings formed therein for differentappurtenances and purposes to be described. When mounted in the fueltank 20, the top portion of the pump housing 102 remains exposed and thehousing is coaxially aligned with vertical mounting axis VA.

Lower housing unit 104 may be configured for mounting and securing thefuel pump 101 thereto. Accordingly, lower housing unit 104 may include aportion which has a complementary configuration to the casing 107 of thepump 101. The upper housing unit 105 may be configured for couplingdirectly to the fuel tank 20 at the fuel fill opening 28. In otherimplementations, the upper housing unit 105 may be indirectly coupled tothe fuel fill opening through an intermediate mounting sleeve or otherelement. When assembled, the pump housing 102 extends for a majority ofthe height, and in some implementations substantially the entire heightof the fuel tank 20 and reservoir 26 from the top wall 21 to a pointsubstantially proximate the bottom wall 22 (allowing for clearance tocouple the fuel filter 103 to the bottom of the pump).

FIGS. 13A-I depict various views of the lower housing unit 104 of thepump housing 102. Lower housing unit 104 includes a top end 205, bottomend 206, and an arcuately curved sidewall 207 extending between theends. In one implementation, lower housing unit 104 may have a generallytubular or cylindrically shaped body having a laterally open side thatmay extend for the entire length of the unit in some configurations.This can be considered to essentially split the lower housing unitapproximately in half lengthwise, thereby defining a semi-circular andgenerally C-shaped body structure with half-tubular or half-cylindricalcross sectional shape as shown. The arcuate sidewall 207 of lowerhousing unit 104 defines a vertical longitudinal concavity 120 on oneside and a convex surface 127 on the opposing side of the body. Theconcavity 120 includes a lower pump receptacle 122 and an upper fuelfill cavity 121. Upper cavity 121 receives fuel dispensed from a fuelingnozzle (e.g. gas can or service station pump) inserted through the tankfill opening 28 and directs the fuel flow substantially downwardly intothe fuel tank reservoir 26 (see, e.g. FIG. 7 directional fuel flowarrows). In some implementations, the upper cavity 121 may bedimensioned so that the end portion of the fueling nozzle may at leastpartially enter the upper cavity. The upper cavity 121 thus is laterallyopen and communicates with the volume of the reservoir 26 when fillingthe fuel tank. Upper cavity 121 may also be upwardly open andcommunicates with the upper housing unit 105 (e.g. internal cavity 155)to define part of the fuel fill fluid pathway P therein and through thepump housing 102 into the fuel tank 20. In one example, withoutlimitation, lower housing unit 104 may be approximately 6 inches longand 2 inches in diameter. Other dimensions may of course be used.

The lower receptacle 122 may be complementary configured to thecylindrical shape of the pump casing 107 so that the pump partiallynests within the receptacle when mounted thereto. In one implementation,the fuel pump 101 may be readily secured to the lower housing unit 104simply with a pair of plastic electrical cable zip ties 129 (see, e.g.FIG. 14B). The convex surface 127 may include arcuately shaped channels128 for securing the zip ties in vertical position on the lower housingunit to prevent slippage (see, e.g. FIG. 13B). The ties can be readilycut if the pump should require removal from the housing and replacement.Other methods of mounting the pump to the lower receptacle 122 of lowerhousing unit 104 may of course be used.

A circular socket 123 is disposed between the lower pump receptacle 122and upper fuel fill cavity 121 for mounting a pressure relief valve 130therein. Valve 130 operates to maintain the pressure of the pumpdischarge fuel flow at a desired preset fuel supply pressure limit, andrelieves any excess pressure by discharging a portion of the fuel fromthe valve back into the fuel tank 20 to prevent over-pressurization ofthe fuel delivery line. Socket 123 is defined by acircumferentially-extending circular wall 124, which may be mutuallyconfigured with the relief valve 130 to secure the valve in place in thesocket. Socket 123 includes an outer section 131 which receives therelief valve body and an inner section 132. Inner section 132 remainsopen beneath the relief valve 130 when the valve is installed anddefines a flow channel through the socket between the lower and upperhousing units 104, 105. The outer section 131 is occupied by the reliefvalve 130 when inserted therein and seated. This also closes the innersection inner section 132 which is in fluid communication with therelief valve 130 for returning a portion of the fuel flow back to thetank reservoir 26. In one configuration, relief valve 130 may begenerally cylindrical and have a step-shaped structure as shown. Outersection 131 of socket 123 may have a complementary configuredstep-shaped structure. Relief valve 130 may be mounted inside the socket123 in any suitable way, for example without limitation interlocked tabsand slots/grooves, threading, or other mechanical coupling means. Themode of attachment is not limiting of the present disclosure.

Socket 123 further includes an inlet port 126 at the bottom of thesocket and an outlet port 134 at top. Inlet port 126 may be circular andconfigured to fluidly and mechanically couple the discharge nozzle 106of the pump thereto. Nozzle 106 may be inserted into the port 126 viaappropriately sized diameters of the nozzle and port. Similarly, outletport 134 may be circular and configured to fluidly and mechanicallycouple to a fuel transfer flow tube 140 which dispenses the pressurizedfuel from the fuel pump assembly 100 through the fuel fill fluid pathwayP. The flow of pressurized fuel in the fuel fill fluid pathway isgenerally upwards while the fuel filling the reservoir of the fuel tankis generally downwards in the fuel fill fluid pathway. Flow tube 140 maybe inserted into the port 134 via appropriately sized diameters of thetube and port. An O-ring seal 135 may be provided to seal the connectionbetween the flow tube 140 and port 134. Ports 126 and 134 may be definedby protrusions 136 extending vertically downwards and upwardsrespectively from the circular socket walls 124. Ports 126 and 134 arein fluid communication with the flow channel 133 extending through thesocket 123, thereby forming a continuously open flow path in the pumphousing 102 from the pump discharge to the discharge flow tube 140.

FIGS. 11A-E depict various views of the fuel discharge flow tube 140.Tube 140 may have a bottom inlet end 141 fluidly coupled to outlet port134 and a top outlet end 142. Outlet end 142 may be angled relative tothe inlet end 141 and forms a flow elbow which dispenses fuel at adifferent angle than received at the inlet end. This allows fuel to bedischarged at a perpendicular or oblique angle to vertical mounting axisVA. The flow tube 140 occupies a portion of the upper fuel fill cavity121, but is fluidly isolated from the cavity. The ends 141, 142 mayinclude diametrically enlarged flanges 143 configured to help retainO-rings mounted thereto for fluidly sealing the tube ends to theirrespective fluid connections in the pump housing. To properly align theinlet end 141 of flow tube 140 with outlet port 134 of the socket 123,the upper end of the lower housing unit 104 may include an upwardly openmounting slot 173. Slot 173 slideably receives a mating downwardly openslot 172 formed proximate to the outlet end 142 of the flow tube 140.

To properly locate the pump 101 in the lower housing unit 104, alaterally and downwardly open slot 137 provided in the housing unitreceives a guide tab 138 formed on the pump casing 107 (see, e.g. FIGS.14A-G). Slot 137 is formed in pump receptacle 122 of the longitudinalconcavity 120. Tab 138 may be formed on the top of the pump casing andprojects vertically upwards therefrom proximate to the pump dischargenozzle 106. In one embodiment, the slot 137 may be defined by aclevis-shaped projection 139 extending downwards from the socket walls124. The slot and tab arrangement helps to axially align the dischargenozzle 106 for insertion into the inlet port 126 of the socket 123 whenthe pump is mounted in the lower housing unit 104.

The upper housing unit 105 of pump housing 102 will now be describedwith additional reference to FIGS. 12A-G. Upper housing unit 105 has acylindrical or tubular body with an annular shape. Upper housing unit105 includes an upper fuel cap mounting section 150 defining a top 151,a lower tank mounting section 152 defining a bottom 153, and cylindricalsidewalls 154 extending between the top and bottom. An internal cavity155 is defined between and penetrates the top and bottom 151, 153defining a top opening 256 and a bottom opening 209 of the housing body.Cavity 155 extends longitudinally along vertical mounting axis VA. Uppersection 150 may be diametrically enlarged relative to the lower section152. Lower section 152 is configured for insertion into and mounting tothe fuel fill opening 28 of the fuel tank 20. The upper section 150remains outside the top of the fuel tank and exposed when the upperhousing unit 105 is fully seated in the fuel fill opening. The uppersection 150 thus doubles as a fuel fill tube for the fuel tank 20. Boththe lower section 152 of upper housing unit 105 and the lower housingunit 104 have diameters which are smaller than the diameter of fuel fillopening of fuel tank 20. This allows these portions of the pump housingto be inserted into the fuel tank reservoir 26 when mounting the pumpassembly to the fuel tank 20.

Lower section 150 of the upper housing unit 105 includes mountingfeatures configured to interact and cooperate with correspondingmounting features formed in the fuel tank 20 within the fuel fillopening 28 for securing the upper housing unit 105 therein. In oneimplementation, lower section 150 includes a plurality of radiallyprotruding lugs 159 which are configured to engage an annular lip 161arranged inside the fuel fill opening 28 (see, e.g. FIG. 21E). Annularlip 161 may be discontinuous to allow inserted of the lugs 159 beneaththe lip. The upper housing unit 105 can then be rotated to lock the lugs159 beneath the lip 161 which prevent axial removal of the housing unit105 from the fuel fill opening 28. In other implementations, the lowersection 150 may threadably engage the fuel tank at the fuel fill opening28. Other types of mechanical coupling mechanisms may be used in otherconstructions.

Upper section 150 includes a fuel dispensing nozzle 157, vent nozzle158, and electrical wiring conduit tube 156 for insertion of electricalpower wires through the pump housing and/or fuel tank to the pump.Nozzle 157 is fluidly coupled to cavity 155 of the upper section viaflow hole 162. Hole 162 is configured for fluid coupling to top outletend 142 of the flow tube 140. This connection may sealed via an O-ring.Fuel discharged by the pump 101 flows through flow tube 140 into thefuel dispensing nozzle 157. A tubing coupler 170 may be coupled tonozzle 157. Coupler 170 is configured for securement of a fuel supplytube thereto via suitable connector, such as without limitation clampsor other means for forming a leak tight fluid coupling. In oneconfiguration, nozzle 157 is insertable into coupler 170 and may befluidly sealed thereto via an O-ring.

With additional reference to FIG. 20, vapor vent nozzle 158 forms partof a fuel vapor removal trap system incorporated into the upper housingunit 105 of pump housing 102. Through natural evaporative properties offuels, fuel vapor will accumulate in the fuel tank 20. Vapor vent nozzle158 allows vapor to pass to the engine, but the trap, formed in part bypassage way 180, separates out any portions of liquid fuel. Nozzle 158is fluidly coupled to both internal cavity 155 of the upper housing unit105 via a top opening and fuel tank reservoir 26 via a bottom opening bya branched internal vent passageway 180 formed through the body of upperhousing unit 105. Passageway 180 includes a vertical section 181 andhorizontal section 182 fluidly communicating directly with the nozzle158. A lower leg of the vertical section 181 of passageway 180 drawsfuel vapor accumulating the top of the fuel tank 20 above the fuelsurface level. An upper leg of the vertical passageway 181 draws vaporthat may accumulate within the internal cavity 155 of the upper housingunit 105. Vertical section 181 may be larger in diameter than horizontalsection 182. This ensures that only vapor is drawn out through the vaportrap, and liquid falls out back into the fuel tank 20. FIG. 20 includesdirection flow arrows showing the flow paths of the vapor moving throughthe trap and drawn out of the vapor nozzle 158 and the liquid fuelflowing downward in the vertical section 181 and returning to the fueltank. The design also provides that the vertical section of the trap issufficiently large, to allow liquid and vapor fuel to occupy the samespace, yet not to be forced together. Gravity will act to pull theliquid fuel down the vertical section 181, and an opening at the bottomof passageway 180 allows the liquid fuel to fall back into the fueltank. Vapor is drawn from an upper-region of the vertical trap, and isshaped with a relatively long horizontal section 182 in communicationwith the vertical section 181. Openings on both the top and the bottomof the trap will give priority to the low resistance vapor, and liquidwill fall away. The horizontal section in communication with thevertical section of the trap is sufficiently long to not completely fillwith liquid, thereby giving time for liquid to fall back into the tankand giving priority to the low resistance vapor which is drawn out ofthe upper housing unit trap system.

As shown by the directional flow arrows, vaporous fuel is evacuated fromreservoir 26 in a first vapor path through the passageway 180 and vapornozzle 158. Nozzle 158 is fluidly connected to a fuel vapor recoverycanister or device, such as a carbon filter operable to handle and treatfuel vapors in the usual manner. A second vapor path is formed from theinternal cavity 155 through passageway 180 and nozzle 158. Vaporsflowing from both directions in the vertical section 181 are combined inthe horizontal section 182 by the bifurcated vapor passageway 180.

Wiring conduit tube 156 provides a pathway for routing a power supplywire (not shown) from an external power supply (e.g. engine-drivendevice/vehicle electrical system) through the upper and lower housingunits 105, 104 of pump housing 102 into the fuel tank 20. This allowsconnection of the power supply wire to the fuel pump 101. Any suitablemeans may be used to connect the pump 101 to the power supply.Non-limiting examples are shown in FIG. 24. One approach is to useconductive pathways 250 integrated into the pump housing 102 to connectthe external source of power to the positive and negative electricalterminals 251, 252 on the pump 101. Alternatively, the power supply maybe wired to the electrical terminals on the pump via conventional wireleads 253. In either case, the external power supply may be introducedinto the housing and fuel tank through the wiring conduit tube 156 ofthe upper housing unit 105. Other types of electrical connections may beused.

The pump 101, filter 103, upper housing unit 105, and lower housing unit104 advantageously may be fully pre-assembled before insertion into thefuel tank 20. Pump 101 may mounted to the lower housing unit 104 in themanner previously described. Filter 103 may be pre-installed on the pumpsuction nozzle 108.

FIGS. 14A-I and 15A-E show sequential views in assembling the pump 101to the pump housing and coupling the upper and lower housing units 105,104 together. FIG. 14A shows the unassembled lower housing unit 104 andpump 101 with filter 103 pre-installed. The pump 101 is then installedand mounted on the lower housing unit as shown in FIG. 14B. Dischargeflow tube 140 is then installed on the lower housing unit as shown inFIG. 14C (either before or after mounting the pump). FIG. 14E shows thepump and flow tube installed. Upper housing unit 105 is axially alignedwith the lower housing unit 104 (FIG. 14F). The top portion of the lowerhousing unit is then inserted through the bottom of the upper housingunit from below as shown in FIG. 14G. The flow tube 140 is then coupledto the fuel dispensing nozzle 157 on upper housing unit 105 via flowhole 162 as shown in FIGS. 14H and 14I. The upper and lower housingunits are now ready to be securely coupled together.

Referring to FIGS. 15A-E, upper and lower housing units 105, 104 arefirst axially aligned. The upper end of the lower housing unit 104 isthen inserted through the open bottom 153 of the upper housing unit 105and into internal cavity 155. Top outlet end 142 of flow tube 140,previously mounted in the lower housing unit 105, is inserted into hole162 of the upper section 150 of the upper housing unit 105. This fluidlycouples the tube to the fuel dispensing nozzle 157. In one construction,the upper portion of the lower housing unit 104 includes a spaced apartpair of lateral guide projections 200 which are inserted intocorresponding guide holes 201 disposed proximate to flow hole 162 insidecavity 155 of the upper housing unit 105 (see, e.g. FIGS. 12F and 13).This ensures that the outlet end 142 of flow tube 140 is properlylocated and aligned for insertion into flow hole 162 of the uppersection 150 of the upper housing unit 105.

Insertion of the lower housing unit 104 into the upper housing unit 105forms an annular gap 210 between the upper and lower housing unitswithin cavity 155 when the units are coupled together. The gap 210extends circumferentially for at least part of the circumference of theupper and lower housing units 105, 104. A retainer 190 configured forinsertion into this annular gap 210 is provided to lock the upperhousing unit 105 to the lower housing unit 104. In one implementation,retainer 190 may have an arcuately curved C-shape Interior end portionsof the retainer 190 may be step shaped to mate with corresponding stepshaped portions of the annular gap. The mutually engaged steps preventthe retainer 190 from rotating within the upper housing unit 105. Inoperation, retainer 190 is placed against the upper portion of lowerhousing unit 104 over the socket 123 and then slid upwards into annulargap 120 within the upper housing unit 105. The retainer 190 may beinserted into the gap for substantially the entire length of theretainer. This frictionally secures the upper housing unit 105 to thelower housing unit 104 via an interference fit created so that the twoparts cannot be axially separated easily with the retainer in place. Theretainer 190 is sized to compress the joint between the upper and lowerhousing units 105, 104, thereby acting a compression fitting. FIGS. 15Eand 16 are top views of the pump housing 102 showing the retainer 190fully seated in the annular gap 120 formed within the upper housing unit105.

In lieu of inserting retainer 190 into annular gap 210 through thebottom of the upper housing unit 105 as shown in FIGS. 15A-E, in someimplementations the retainer may instead be inserted into the gap 210from the top of the upper housing unit. This is illustrated in FIG. 15F.The upper housing unit 105 in this case is configured to allow insertionof the retainer through its top opening 256.

Electrical wiring connections may now be made to pump 101 via wiringconduit tube 156 before the pump assembly is installed in the fuel tank20. In alternative constructions, the upper housing unit 105 and lowerhousing unit 104 may have complementary configured mating male/femaleelectrical terminals (not shown) to automatically make the necessaryelectrical connections to the pump when the upper and lower housingunits are coupled together. The terminals may in turn be wired to thepump 101 and length of electrical wires inserted through wiring conduittube 156.

The fuel cap 30 may next be mounted on the fuel tank 20 by rotarycoupling to the top end of the pump housing 102. Referring to FIGS.19A-D, fuel cap 30 is an assembly comprising a circular upper operatingportion 192 and a lower coupling portion 193 configured for coupling tothe upper housing unit 105 of the pump housing. Operating portion 192may be configured for grasping by a user and has a diameter larger thanthe diameter of the upper housing unit 105. Coupling portion 193 has adiameter smaller than the upper housing unit 105 to allow insertion intothe internal cavity of the upper housing unit.

With continuing reference to FIGS. 19A D, upper housing unit 105 of pumphousing 102 is configured for removably mounting the fuel cap 30thereto, thereby forming a tank fuel fill port or tube. This provision,along with the configuration of the lower housing section 104 (e.g.upper fuel fill cavity 121) advantageously allow a single fuel tankopening to be used for both mounting the fuel pump and fuel fill. Uppersection 150 of housing unit 105 and fuel cap 30 each includecomplementary configured mechanical coupling features which allowremovable coupling of the fuel cap to the pump housing. In one example,fuel cap 30 may be rotatably and threadably attached to the uppersection 150 of the upper housing unit 105. In another possiblearrangement as illustrated, a cam lock type configuration may be used torotatably secure the fuel cap 30 in place on the upper housing unit 105.Upper section 150 of upper housing unit 105 may include a pair ofcircumferential cam lock tracks or grooves 177. Grooves 177 may beinwardly open to cavity 155 and diametrically opposed. Grooves 177 maybe formed in the lateral sidewalls 154 of the upper section 150. In oneimplementation, cam lock grooves 177 each have a circumferentiallymeasured length or extent that is about one-half or less than thecircumference of the upper section 150 (i.e. angularly about 180 degreesor less). Each groove 177 has an open entry end 179 and closed end 178formed by an end wall. The entry ends 179 each communicate with anentrance slot 160 formed through an annular top surface 175 of the upperhousing unit 105. The pair of slots 160 may be diametrically opposed andreceive pair of diametrically opposed camming lugs 176 formed at or nearthe bottom end 178 of the fuel cap assembly. Camming lugs 176 protruderadially and laterally outwards from the fuel cap assembly. In use, thefuel cap assembly is axially inserted into the internal cavity 155 ofthe upper housing unit 105. Camming lugs 176 are aligned with andinserted through the slots 160 into the groove 177. The fuel cap 30 isthen rotated. The lugs 176 each slidably engage and travelcircumferentially in their respective cam lock grooves 177 from theentrance slots 160 to a respective closed end 178 of each groove. Thisprevents the fuel cap 30 from further rotation and locks the cap inplace on the fuel tank 20. In one configuration, the cam lock grooves177 may each be angled or sloped downwards from the entry ends 179 tothe closed ends 178 (best shown in FIG. 12D). As the fuel cap 30 isturned, the rotary motion of the lugs 176 in the sloped grooves 177draws the fuel caps axially downward to tighten engagement with theupper housing unit 105. Fuel cap 30 may include suitable seals andappurtenances for sealing the connection to the upper housing unit 105.

FIGS. 21A-F show sequential steps in a process or method for installingthe fully-assembled fuel pump assembly (with or without fuel cap 30 inplace on the pump housing) into the fuel tank 20. Fuel pump assembly(inclusive of the pump housing 102, pump 101, and filter 103) isvertically and axially aligned with the fuel fill opening 28 in fueltank 20 along vertical mounting axis VA (FIG. 21A). The fuel filter 103is in its normal unfolded flattened (i.e. undeformed/undeflected)condition or state with ends 109 protruding laterally outwards beyondthe pump housing 102. The bottom end of the lower housing unit 104 andfilter are slideably and vertically inserted into the fuel fill opening28. Filter 103 engages fuel tank 20 at the fuel fill opening 28, whichcauses the ends 109 of the filter to fold upwards into approximately aU-shaped configuration (FIG. 21B). This conforms the filter to the sizeof the opening temporarily to allow the pump housing to be fullyinserted into the tank 20. Once the pump housing 102 is inserted to asufficient depth into the fuel tank 20 (FIG. 21C), the ends 109 offilter 103 will pass beneath and disengaged the tank fuel fill opening28 and spring back to their original unfolded flattened condition.

Once the pump assembly is fully lowered and inserted into the fuel tank30 (FIG. 21D), the pump assembly may then be rotated about 90 degrees inone example to lock the pump housing 102 to the fuel tank 30 (FIG. 21F).This is accomplished via the radially protruding lugs 159 on the upperhousing unit 105 engaging the annular lip 161 arranged inside the fuelfill opening 28 of the fuel tank 20 (FIG. 21E). Vertical axial removalof the pump assembly from the fuel fill opening 28 is prevented withoutrotating the pump assembly back to its original insertion orientation.The pump housing nozzles 158, 157, and electrical conduit tube 156 arenow axially aligned with a protective tubing channel 198 mounted on thetop of the fuel tank 30. Only the bottom section of the tubing channelstructure is shown for clarity of depiction; however, a mating topsection which may have the same configuration as the bottom section maythen be coupled to the bottom section to fully enclose and protect thenozzles 157, 158 and electrical conduit tube 156 from damage. The fuelline and vapor line runs between the fuel pump assembly and the engineand vapor canister may next be coupled as required. It bears noting theelectrical wiring connections to pump 101 via wiring conduit tube 156may be made before the pump assembly is installed in the fuel tank 20during assembly of the pump housing as previously described herein.

Advantageously, the pump housing 102 is configured so that the fuel tank20 may be filled with fuel with the fuel pump assembly remains installedin the fuel fill opening 28 of the tank. This is provided by the fuelfill flow path P defined through the pump housing as previouslydescribed herein. The dual purpose fuel fill opening, used for bothfilling the tank with fuel and mounting the pump assembly therein,obviates the need for a separate pump opening.

FIG. 22 is a schematic diagram showing an engine-operated device orapparatus with liquid fuel delivery system according to the presentdisclosure. The apparatus may be any type of vehicle or equipment whichoperates on liquid fuel. For example, the vehicle may include wheel,rotating tracks, or propellers for creating propulsion to translate thevehicle across a surface or body of water, such as for example withoutlimitation a riding mower, snowmobile, boat, all-terrain vehicle (ATV),automobile, etc. In other possible implementations, the apparatus may bea stationary piece of equipment a power generator, farm equipment, yardequipment, or other. The type of engine-operated apparatus is notlimiting of the present disclosure. The apparatus may include aninternal combustion engine configured to combust liquid fuel such asgasoline which may be stored in tank 20 mounted on-board. Tank 20includes a fuel pump assembly according to the present disclosureincluding pump housing 102, pump 101, and filter 103. The pump housing102 includes fuel dispensing nozzle 157, vapor vent nozzle 158, andelectrical wiring conduit tube 156. The fuel dispensing nozzle 157 isfluidly coupled to the engine via the fuel tubing or line. Vent nozzle158 is fluidly coupled to the fuel vapor canister via the vapor tubingor line. Fuel pump 101 (not individually shown in FIG. 22) of the fuelpump assembly may be electrically connected to the device/vehicle powersupply system via suitable wiring and wiring conduit tube 156. Thepressurized fuel line travels directly to the fuel injector. The fuelinjector may go into an air-mixer throttle body, or into intakemanifold, or may go directly in-cylinder (for direct-injection scheme).The vapor line continues from carbon canister (or AKA “vapor canister”)to the air intake for the engine. Fuel vapors, which were temporarilystored in the absorptive carbon, will be re-evaporated into an airstream to the engine, thereby digesting all fuel completely during thenormal combustion process. In operation, the pump assembly pumps fuelfrom tank 20 to the fuel injection system of the engine based on theposition of the throttle. Vaporous fuel accumulating in the tank flowsto the vapor canister, and then travel from the canister to the intakeof the engine for digestion in the combustion process. Theengine-operated apparatus includes all other components andappurtenances necessary for a fully functional liquid-fuel poweredapparatus.

FIGS. 23A-D depict an alternative carbon canister fuel cap 220 usablewith the fuel pump assembly 100. Fuel cap 220 has a higher profile thanfuel cap 30 that defines an internal chamber 221 configured to house acarbon fuel vapor canister 222 for treatment of vaporous fuel emissions.Fuel cap 220 may be similar to fuel cap 30 in all other aspectsincluding the provision of camming lugs 176 to fasten the cap to theupper housing unit 105 of pump assembly 100, as previously describedherein.

While the foregoing description and drawings represent exemplaryembodiments of the present disclosure, it will be understood thatvarious additions, modifications and substitutions may be made thereinwithout departing from the spirit and scope and range of equivalents ofthe accompanying claims. In particular, it will be clear to thoseskilled in the art that the present invention may be embodied in otherforms, structures, arrangements, proportions, sizes, and with otherelements, materials, and components, without departing from the spiritor essential characteristics thereof. In addition, numerous variationsin the methods/processes. One skilled in the art will further appreciatethat the embodiments may be used with many modifications of structure,arrangement, proportions, sizes, materials, and components andotherwise, used in the practice of the disclosure, which areparticularly adapted to specific environments and operative requirementswithout departing from the principles described herein. The presentlydisclosed embodiments are therefore to be considered in all respects asillustrative and not restrictive. The appended claims should beconstrued broadly, to include other variants and embodiments of thedisclosure, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents.

What is claimed is:
 1. A fuel pump assembly comprising: a pump housing configured for mounting to a fuel fill opening of a fuel tank, the fuel fill opening configured for adding fuel to the fuel tank; at least a portion of the pump housing comprising an internal cavity defining a fuel fill fluid pathway between the fuel fill opening and an interior of the fuel tank, the cavity configured for receiving and adding fuel from an external fuel source to the fuel tank via the fuel fill opening; and a fuel pump mounted to the pump housing for dispensing fuel from the fuel tank through the fuel fill opening.
 2. The pump assembly according to claim 1, further comprising a discharge flow tube fluidly coupled to the fuel pump for discharging the pressurized fuel from the pump, the discharge flow tube routed through the fuel fill fluid pathway in the pump housing.
 3. The pump assembly according to claim 1, wherein the pump housing comprises an upper housing unit and a lower housing unit detachably coupled thereto.
 4. The pump assembly according to claim 3, wherein the lower housing unit is partially inserted and received inside the upper housing unit forming an annular gap therebetween.
 5. The pump assembly according to claim 4, further comprising an arcuately curved retainer inserted in the annular gap which frictionally secures the lower housing unit to the upper housing unit.
 6. The pump assembly according to claim 3, wherein the upper housing unit is configured for coupling to the fuel fill opening of a fuel tank and includes a removable fuel cap which closes a top opening of the upper housing unit to the fuel fill fluid pathway.
 7. The pump assembly according to claim 3, wherein an internal cavity of the pump housing in the upper housing unit defines an upwardly open portion and downwardly open portion of the fuel fill fluid pathway through the pump housing.
 8. The pump assembly according to claim 3, wherein the lower housing unit has a semi-circular half-tubular body comprising an arcuate sidewall defining a vertically-elongated concavity on a first side and a convex surface on an opposite second side, the concavity being laterally open.
 9. The pump assembly according to claim 8, wherein the pump is mounted in a lower portion of the concavity and an upper portion of the concavity is disposed in the upper housing unit forming part of the fuel fill fluid pathway.
 10. The pump assembly according to claim 9, wherein the lower housing unit includes a circular socket formed between the lower and upper portions of the vertical concavity, and further comprising a pressure relief valve disposed in the socket.
 11. The pump assembly according to claim 1, wherein the upper housing unit includes a fuel dispensing nozzle, a vent nozzle, and an electrical wiring conduit tube each extending laterally from the upper housing unit.
 12. The pump assembly according to claim 1, further comprising a laterally extending elongated fuel filter mounted to a suction nozzle of the pump, the filter being resiliently deformable between a folded condition and a flattened unfolded condition.
 13. The pump assembly according to claim 12, wherein the filter has a lateral width larger than a diameter of the fuel fill opening in the fuel tank when the filter is in the unfolded condition.
 14. The pump assembly according to claim 1, wherein the fuel fill opening and cavity are collectively configured for at least partial insertion of a fueling nozzle therein associated with the external fuel source to direct the fuel dispensed from the fueling nozzle through the pump housing and into the fuel tank.
 15. A fuel supply system comprising: a tank including a reservoir for holding fuel and a fuel fill opening fluidly communicating with the reservoir, the fuel fill opening configured for adding fuel to the fuel tank; a fuel pump system mounted in the tank through the fuel fill opening, at least a portion of the fuel pump system comprising a housing defining an internal cavity and fuel fill fluid pathway between the fuel fill opening and the reservoir, the cavity configured for receiving and adding fuel from an external fuel source to the fuel tank via the fuel fill opening; and the fuel pump system comprising a fuel pump disposed in the reservoir, the fuel pump operable to dispense fuel from the tank through the fuel fill opening.
 16. The fuel supply system according to claim 15, further comprising a resiliently deformable elongated fuel filter coupled to a suction nozzle of the pump, the fuel filter changeable between a flattened unfolded condition and a folded condition.
 17. The fuel supply system according to claim 15, wherein the fuel pump system comprises a pump housing including an upper housing unit rotatably coupled to the fuel fill opening in the fuel tank and a lower housing unit removably coupled to the upper housing unit, the fuel pump mounted to the lower housing unit.
 18. The fuel supply system according to claim 15, further comprising a discharge flow tube disposed in the fuel fill fluid pathway and arranged to receive fuel from the fuel pump.
 19. The fuel supply system according to claim 15, wherein the fuel tank has a unitary monolithic construction.
 20. A method for mounting a fuel pump in a fuel tank, the method comprising: providing a pump housing including the fuel pump and an inlet fuel filter coupled to the fuel pump, the filter being resiliently deformable between a flattened unfolded condition and a folded condition; the pump housing comprising an internal cavity configured for receiving and adding fuel from an external fuel source to the fuel tank via a fuel fill opening in the fuel tank; aligning the pump housing with the fuel fill opening in the fuel tank, the filter being in the unfolded condition; inserting a lower portion of the pump housing through the fuel fill opening; engaging the filter with the fuel tank at the fuel fill opening, the engagement collapsing the filter from the unfolded condition to the folded condition; and spreading the filter from the folded condition to the unfolded condition once the filter disengages the fuel tank at the fuel fill opening; wherein the pump housing is positioned through the fuel fill opening.
 21. The method according to claim 20, further comprising rotatably coupling the pump housing with the fuel fill opening to secure the pump housing to the fuel tank. 